Method of making a composition and nanocomposites therefrom

Abstract

A mixture of layered silicate, block copolymer having at least one block that is compatible with the first layered silicate, and a solvent is sheared while the solvent is removed.

1. A method of making a composition, the method comprising:
 mixing components comprising a first layered silicate having a first d-layer spacing, a block copolymer having at least one block that is capable of intercalating the first layered silicate, and a solvent to provide a first mixture, wherein the first mixture contains from at least 10 percent by weight of the solvent, based on the total weight of the first mixture; 
 kneading the first mixture under vacuum using a vacuum kneader while removing the solvent from the first mixture to provide a second mixture comprising from about 0.2 to about 0.5 percent by weight of the solvent, based on the total weight of the second mixture, the kneading comprising contacting the first mixture with a kneading member, wherein the second mixture comprises the block copolymer having dispersed therein at least one of: 
 a) a second layered silicate having a second d-layer spacing resulting from intercalation of the first layered silicate by the block copolymer, the second d-layer spacing being greater than the first d-layer spacing; or 
 b) exfoliated silicate platelets. 
 
     
     
       2. A method according to  claim 1 , wherein the solvent does not swell the first layered silicate. 
     
     
       3. A method according to  claim 1 , wherein the total amount of the second layered silicate and exfoliated silicate platelets comprises at least 30 percent by weight of the second mixture. 
     
     
       4. A method according to  claim 1 , wherein the total amount of the second layered silicate and exfoliated silicate platelets comprises at least 40 percent by weight of the second mixture. 
     
     
       5. A method according to  claim 1 , wherein the total amount of second layered silicate and exfoliated silicate platelets comprises at least 50 percent by weight of the second mixture. 
     
     
       6. A method according to  claim 1 , wherein the total amount of second layered silicate and exfoliated silicate platelets comprises at least 60 percent by weight of the second mixture. 
     
     
       7. A method according to  claim 1 , wherein the method is carried out in a continuous manner. 
     
     
       8. A method according to  claim 1 , wherein the block copolymer comprises a diblock copolymer. 
     
     
       9. A method according to  claim 1 , wherein the block copolymer comprises a highly fluorinated block. 
     
     
       10. A method according to  claim 1 , wherein the block copolymer is selected from the group consisting of poly(styrene-block-4-vinylpyridine), poly(styrene-block-isoprene-block-4-vinylpyridine), poly(styrene-block-butadiene-block-4-vinylpyridine), poly(isoprene-block-4-vinylpyridine), poly(butadiene-block-4-vinylpyridine), hydrogenated versions of poly(butadiene-block-4-vinylpyridine), poly(styrene-block-isoprene-block-4-vinylpyridine), poly(styrene-block-butadiene-block-4-vinylpyridine), and poly(isoprene-block-4-vinylpyridine). 
     
     
       11. A method according to  claim 1 , wherein the layered silicate comprises montmorillonite, nontronite, bentonite, beidellite, hectorite, saponite, sauconite, fluorohectorite, stevensite, volkonskoite, magadiite, kenyaite, halloysite, hydrotalcite, a synthetic layered silicate, or a combination thereof. 
     
     
       12. A method according to  claim 1 , wherein the layered silicate comprises an organoclay. 
     
     
       13. A method according to  claim 1 , further comprising mixing the second mixture with a polymeric resin to provide a nanocomposite, wherein the nanocomposite comprises a exfoliated silicate platelets dispersed in the polymeric resin. 
     
     
       14. A method according to  claim 13 , wherein the method is carried out in a continuous manner. 
     
     
       15. A method according to  claim 13 , wherein the polymeric resin comprises a thermoplastic resin. 
     
     
       16. A method according to  claim 13 , wherein the polymeric resin comprises a thermosetting resin. 
     
     
       17. A method according to  claim 13 , wherein the polymeric resin comprises an elastomeric resin. 
     
     
       18. A method according to  claim 13 , wherein the polymeric resin comprises a polyolefin, polyurethane, polyamide, fluoropolymer, polyimide, polycarbonate, polyester, polysulfone, polylactone, polyacetal, acrylonitrile copolymer, polyphenylene oxide, polyphenylene sulfide, polystyrene, aromatic polyketone, or a combination thereof. 
     
     
       19. A method according to  claim 13 , wherein the polymeric resin comprises a polyolefin. 
     
     
       20. A method according to  claim 13 , wherein the weight ratio of the polymeric resin to the block copolymer is in a range of 20 to 200, inclusive. 
     
     
       21. A method according to  claim 13 , wherein the weight ratio of the exfoliated silicate platelets to the second layered silicate in the nanocomposite is at least one. 
     
     
       22. A method according to  claim 13 , wherein the exfoliated silicate platelets are contained in the nanocomposite in an amount of from 1 to 5 percent by weight, inclusive, based on the total weight of the nanocomposite.